Formed paper dish and method for making same



Aug. 29, 1961 R. H. CARSON 2,997,927 A FORMED PAPER DISH AND METHOD FOR MAKING SAME Filed Feb. 9, 1959 3 Sheets-Sheet 1 //vv:/v TOR ROBERT H OARso/v A TTORNE y 1961' R. H. CARSON 2,997,927

FORMED PAPER DISH AND METHOD FOR MAKING SAME Filed Feb. 9. 1959 I 3 Sheets-Sheet 2 A TTORNEY r m Q /NVENTOR Q ROBERT/7. CARSON R. H. CARSON FORMED PAPER DISH AND METHOD FOR MAKING SAME Filed Feb. 9, 1959 1 6 9 1 9 2 a u A 3 Sheets-Sheet 3 //VVENTOR ROBERT l-z' CARS-0N 5, W m

ATTORNEY United States Patent-O Patented Aug. 29, 1961 1 2 2 997,927 g a back-up roll 26, these two rolls 2S and 26 serving 9 as means for propelling the paper 22 over a table FORMED fi'iggg Win01) FOR or bed plate 27. The roll 25 will be intermittently driven,

Robert H. Carson, Marion, Ind., assignor to Peerless Machine & Tool Co., Inc., Marion, Ind., a corporation of Indiana Filed Feb. 9, 1959, Ser. No. 791,920 Claims. (Cl. 93-36) comers in encircling walls, or arcuate surfaces as in the sides of bowls. While the invention is particularly useful in deeply formed dishes, it also finds an avantageous use in shallow dishes.

The dish made in accordance with the present inven tion, will have curved zones wherein the paper is taken up not in overlapping folds as is heretofore been the case, but in closely abutting, side by side rectangular,

folds in a very smooth, uniform manner, not only taking up the excess paper in such zones, but eliminating the highly undesirable overlaps.

These rectangular folds are produced by initially scoring the zone to be formed by pressure and not by cutting, in a very definite and regular manner, such as by long scores with intervening shorter scores, all as will be more fully explained below.

In describing the invention, reference is made to the accompanying drawings, in which FIG. 1 is a view in diagrammatic form of a method of producing a plate embodying the invention;

FIG. 2 is a view in top plan of the diagrammatic representation in FIG. 1;

FIG. 3 is a section on the line 33 in FIG. 1;

- FIG. 4 is a section on the line 44 in FIG. 1;

FIG. 5 is a view in top plan of a blank prior to form- FIG. 6 is a view of a dish formed from the blank of FIG. 5, in top plan;

FIG. 7 is a view in side elevation of the dish shown in FIG. 6;

FIG. 8 is a view in enlarged scale of a corner of the dish of FIG. 6;

FIG. 9 is a view in section on the line 9-9 in FIG. 5 on an enlarged scale;

FIG. 10 is a view of a scored blank for a circular dish;

FIG. 11 is a fragmentary portion of a circular blank for a deep bowl; and

FIG. 12. is a detail of a circular plate wherein there are shown scores for ultimate curving of the rim of a dish above the floor thereof.

so that the paper 22 will come to a stop at predetermined intervals of feed over the table 27, for scoring, corner cutting, and cut-off, either simultaneously or, as herein indicated, in sequence.

A die 28 will come into compressive contact with the paper 22 over the table 27 and score the paper 22 to impress into the paper-score lines'at zones 29 in a pattern which will hereinafter be more fully explained, it being suflicient for the time being to state that the zones'are centered on the lines 30 which are the lines along the cuts through the paper 22 produced by the rolling cutters 31 on the slitter roll 25.

A corner cutting die 32 may be incorporated with the scoring die 28, or may be separate therefrom as is herein shown, to cut through the central portions of the zones 29 as at 33, FIG. 2.

While the paper 22 is intermittently stopped on the table 27 in the strips designated by the numeral 34, the

Referring first to FIGS. 1-4, the dishes to be formed popularly termed as cardboard. Also the paper in the roll 15 has either been treated to have a rather high degree of moisture, or moisture is added to the paper in the web 16 leaving the roll 15 as may be desired in the particular plant wherein the dishes are to be formed. In the usual procedure, the web 16 will be carried through straightening rollers 17, 18, and 19 and between drive rollers 20 and 21. From the drive rollers 20, 21, the paper generally designated by the numeral 22 will be carried through a loop 23 and thence over a roller 24, between a slitter roll 25 various strips are simultaneously sheared by any suitable means, such as by the knives 35 and 36, transversely of the strips 34 and centrally of the zones 33. to produce the individual blanks 37, herein shown as four in number, one for each of the four strips 34. The number of these strips 34 are of course arbitrary and may be any number which may be desired and which will fit the apparatus of the individual installation.

The blanks 37 are fed to forming dies by any suitable means, herein shown as sliding down a die holder 38 under the influence of gravity. The holder 38 carries a plurality of female dies 39, and a blank drops into these dies 39. A male die portion 40 is then carried down wardly against the blank to form it within the die portion 39, to produce the finished dish designated by the numeral 43. The die portions 39 and 40 have rounded corners, perfectly smooth and not fluted or ridged in any respect. For example, the female die 39, FIG. 4, has the rounded corners 41 whereas, FIG. 3, the male die 40 has the rounded corners 42. Some means for ejecting the dishes from the die portions 39 upon the lifting of the portions 40 is incorporated in the well known and usual manner, and hence is not shown since it does not form a part of the invention per se. Also it is to be noted, that these die portions, at least one of them, is provided with an electric heating element in order to dry out the paper of the dish while it is being formed so that the paper will take a permanent set in the formed condition. These dishes 43 will drop downwardly from the member 38 to be gathered by any suitable manner such as by a belt conveyor 44.

Reference is now made to FIGS. 5-9. A blank 37 is illustrated in FIG. 5 in its flat condition to illustrate the corner scoring. Since the blank 37 is to form a dish substantially rectangular with rounded corners, the scoring is limited to a ninety degree portion at each corner of the rounded portions. Beginning at a line 46 which extends at right angles to the straight edge portion 47, and substantially at the juncture of the curved edge 47a, this line 46 extends inwardly to terminate substantially at'what will be the line of bend 52, FIG. 6, from which the flared wall 54 extends outwardly and upwardly. Then next adjacent to the line 46 is a line 48 which is approximately one-half the length of line 46, and following which line 48 there is a second line 46 spaced the same distance from the line 48 as is the line 48 from the line 46. These score lines are thus placed alternately around the curved portion 47a, and are on radii extendingfrom the center 51 so that the last line 46a will be perpendicular to the end edge 50.

Referring specifically to FIG. 9, the detail in section illustrates the contour of the scoring of the lines 46 and 48 in the blank 37, wherein the impressions in the blank 37 are not sharp line depressions but rather arcuate as illustrated. f,

The wall 54 is turned upwardly from the flat area of the floor 53, and instead of the paper tending to fold into overlapping arrangement in the corners, the paper will, peculiarly, form itself between the si'nooth surfaces of the two die sections at their corners into a regular series of rectangular pleats or folds 55 extending outwardly from the outside of the wall 54 as best indicated in FIG. 8. The only visible indication of the fold from the inside of the wall are lines 56 and 57 defining the lines of abutment between the folds, the surfaces of which folds on the inside of the wall 54 are in a continuous smooth surface around the corner. These lines56 and 57 correspond to the lines 46 and 48 which, however, are at the inner bottom sides of the folds -158 and 59.

Another peculiarity of this folding without overlapping is indicated in FIG. 7, where there lis'l a long fold shown and designated by the numeral 58 exte'n ing from the top to the bottom of the wall 54, this fol 58 being centered on the line 46 in each instance, and there is a shorter fold 59 centered on the shorter line 48 in each instance. The shorter folds 59 terminate very nicely on a rounded end 60 apparent from the outside, but not apparent from the inside, the only indication thereof from the inside being the shorter line 57 in each case.

Reference is made to FIG. 9 particularly now in that these lines 46 and 48 around the scored zone of the blank 37 are not sharp lines, but in etfect rounded so that the fiber of the blank 37 is not cut nor damaged, but only compressed in the scored line zones. These scores 46 and 48 are very definitely indentations inth face of the blank 37, and not merely imprinted lines or the like.

Reference has been made to the dish 43 wherein, as indicated in the drawing, the depth of the Wall 54 gives a rather shallow dish. Where these walls 54 are to be increased in height, the same procedure is held and the only difference is that the score lines would be continued up the increased heigbt'pf 'what will become the wall eventually, as indicated by the dash lines in FIG. 8 extending outwardly from the solid lines. However, if this depth of wall becomes quite considerable, such as might be employed in a bowl, a variation in the scoring will be employed such as is indicated in FIG. 11. In this case, there will be a greater difference between adjacent lines 46, 48 and 46, and the distances there between are divided equally to receive the shorter lines 45, one on each side of the line 48, there being .tw pf-the lines 45 between adjacent lines 46.

It is important that these lines 48 and 46 as well as 45 be not spaced too far apart, else there will be a tendency for the paper to fold over onto itself and not follow the regular, rectangular fold as indicated in FIGS. 6 and 8. Neither is it desirable to have the rectangular shaping to be spaced too far apart, that is, one external rib from the other, else these ribs would extend too far out beyond the outer surface of the wall, or would be damaged in the forming operation by the dies. For example, FIG. 5, the

spacing apart of one line 46 from the next adjacent line 46 abound the margin 47a would be on the order of of an inch, but upon the deeper fold formation, these lines would be approximately twice that far apart on the margin, these dimensions, of course, are approximations, and may vary depending upon the thickness of the paper as well as the depth of the wall or the depth of the curved portion being formed.

The scoring lines 46, 48 and as indicated in FIG. ll, 45, divide up the area which is to be curved into small increments of area defined between these lines so that there will be an even, equal flow of the paper absorbed in each of these small units or increments. It is through the use of these defined increments by the score lines, that the large overlap folding of a considerable area of ators, it is impossible to set up a definite depth of the scoring which will held under all conditions. The deeper the dish, the more advantageous becomes the present invention.

Reference is made to FIG. 10, wherein a circular blank 61 is indicated, and it is desired to form a wall turned upwardly and diagonally therefrom in the finished dish. The lines will be radially placed as indicated with the short line intervening between the two longer lines. Reference to FIG. 12 is made to show what the scoring lines would be in a dish such as a compartmental dish wherein there is a wall portion 62 to be turned upwardly from the floor 63 on the circumferential line 64, and from the top portion of which, centered on the circumferential line 65, a flange 66 is to be turned outwardly from the top of that wall through a curved portion, and finally the outer margin is to be rounded around and downwardly, the score lines being provided around the periphery of the blank accordingly. In other words, any curved zone of a blank will be scored in like manner so that when the blank is carried to the die, the paper will come into the rectangular pleats or folds without any overlapping arrangement. The excess paper is always taken up through this curved zone in the rectangular formation as predetermined by the positioning of the score lines.

Therefore while I have shown my invention in the several particular forms, it is obvious that variations may be employed in the method as well as in the final product all without departing from the spirit of the invention, and I therefore do not desire to be limited to those particular forms beyond the limitations which may be imposed by the following claims.

I claim:

1. The method of forming a curved wall portion extending from a zone of a paper dish without overlapping folds, which method comprises impressing on a planar, moistened paper dish blank in an area of a face thereof which will be on the inside of the dish and which area will eventually constitute that of the curving wall portion, a series of spaced, side by side, linear indentations extending approximately radially from near a margin of said zone outwardly toward the margin of said blank; introducing the planar, indented blank between a pair of dish forming male and female members, each having a complementary rounding, smooth surface for shaping said wall portion and spaced one surface from the other by a clearance exceeding that of said blank; moving said members one toward the other drawing said blank area intd said members spacing around the smooth surface of at least one of said members and causing a flow of paper in said blank area between said member smooth surfaces into an approximately rectangular, spontaneous fold around each of said indentations, to fold protruding from that outer-side of the blank opposite to the inner side carrying the indentations and carrying the indentation within the fold in each instance a distance from said inner side; and continuingly moving said members one toward the other ultimately compressibly engaging the blank inner wall side and said outer side folds between said smooth rounding surfaces and pressing, through the folds, and the said blank inner side face laterally across said indentations into a substantially smooth inner face around said curved wall portion.

2. The method of claim 1 in which said indentations are formed in a design around the wall portion with short,

lines of indentations between longer lines, all of said lines terminating at said blank outer margins.

3. The method of claim 1 in which said dampened blank is heated upon the final compressing of the blank between said member surfaces.

4. The method of forming a curved wall portion extending from afloor zone in a paper dish in the absence of overlapping folds, which method comprises cutting a planar dish blank from moistened paper; impressing on the blank around an area thereof which will lie on the inside of said wall portion to be formed, a series of spaced apart, side by side linear indentations extending from near a margin of said zone to the outer edge of said blank wall portion, said indentations being impressed approximately radially in said wall portion area from said zone; pressing the indented blank between male and female members, each having a matching smooth rounding surface for shaping said wall portion and spaced one from the other a thickness exceeding that of said paper blank and freely receiving therebetween initially said wall portion; continuing said pressing while said blank wall portion spontaneously goes into an approximately rectangular folded formation within said member spacing and extends from the outermost side of said dish wall, the folds extending to the outside of the blank wall with said indentations being therewithin and shaping under said pressure to center one fold each on said indentations; and

said pressing being ended upon traveling together of marginal lines of the folds at the inside of said curving wall portion, and between said folds, one line into approximate contact with the other centered over said indentations, providing an inner, continuous contour around said curved portion wall.

5. The method of claim 4 in which said pressing between said members is continued to that degree which will compress said folds against the outer side of said wall portion and urge the paper inwardly of the blank fro'm the outside thereof to efl ect said traveling together of said marginal lines over said indentations.

References Cited in the file of this patent UNITED STATES PATENTS 1,435,149 Carle Nov. 14, 1922 1,737,789 Fine Dec. 3, 1929 1,915,164 Orem et a] June 20, 1933 2,047,284 Morris July 14, 1936 2,248,534 Meyer-Iagenberg et al July 8, 1941 2,393,347 Stuart Ian. 22, 1946 2,763,421 Bennett Sept. 18, 1956 2,831,623 Lavigne Apr. 22, 1958 FOREIGN PATENTS 483,183 Germany Sept. 27, 1929 

